Method of and means for forming flanged articles



Jan. 21, 1930. R. K. HOPKINS METHOD OF AND MEANS FQR FORMING FLANGEDARTICLES Filed Sept. 29, 1927 2 Sheets-Sheet O/ d rolled produc+ H '1Original blcmlf Jan. 21, 1930.

R. K. HOPKINS METHOD OF AND MEANS FOR FORMING FLAI IGED ARTICLES FiledSept. 29, 1927 2 Sheets-Sheet 2 avwemtoz Patented Jan. 21, 1930 UNITEDs'm Es PATEN'T OFFICE- ROBERT KINGSLEY HOPKINS, OF NEW YORK, N. Y.,ASSIGNOR TO THE. M. W. KELLOGG COMPANY, A CORPORATION OF DELAWARE METHOD01? AND MEANS FOR FORMING FLANGED ARTICLES Application filed September29, 1927. Serial No. 222,786.

The present inventionrelates to a process of, and apparatus for, formingflanged articles, and in particular to the forming of annular flangeswith hubs.

a In forming flanged articles, and particularly where the flangedportion is relatively wide and the ratio of thethickness of the body ofthe article to that of the flanged portion is large, the methodsheretofore employed have required recourse'to considerable machiningwork to bring the article down to finished dimensions. to the fact thatthere is an unequal distribution of metal between the flanged portionand the body portion, and in following any. of

the methods heretofore proposed forreducing the section of the blankboth in the .flanged portion and the body portion by rolling or forgingit has not been possible to bring about the elongation of the respectiveportions at the same rate. This is particularly true when rollingannular flanges having high hub portions and where the ratio of theflange thickness to the hub thickness is large.

According to the present invention the flanged article, such forexample, as an annular flange having a high hub portion, is rolled insuch a way that the hub and the is to say, the percentage of reductionof each is the same. In this way an article rolled to its finisheddimensions may be produced. Also by causing the various portions of thearticle to grow proportionally, thesetting up of undesirable stresses inthe metal is avoided.

The invention also includes a roll of special construction and means forassociating it with rolls of more or less standard construction in sucha way as to carry out the method above described.

In the drawings:

Fig. 1 is a section through an annular billet of a type suitable for usein rolling flanges.

Fig. 2 is a section showing the billet illustrated in Fig-1 after it hasbeen rolled according to the practice heretofore employed and with thedimensions of the finishedfiange indicated in dotted .lines.

This is due flanged body elongate at the same rate; that Y Fig. 3 showsa section of a billet similar to that shown in Fig. 1,-together with arepresent-ation, superimposed thereon in dotted lines, of the flange atthe end of the rolling operation, and also showing the position the rolloccupies at the beginning of the rolling operation and its course duringthe period in which the billet is being reduced to a flange of thedesired dimensions.

Fig. 4 is similar to Fig. 3 except that a billet-with a hub is shown.

Fig. 5 is a side elevational view of an ap paratus embodying the presentinvention with a blank shown in section and in position to be rolled.

Fig. 6 is a side elevational View of a moditied form of apparatus with ablank shown in section in position to be rolled similarly as in Fig. 5.

Fig. 7 is a top plan view of the apparatus shown in Fig. 5. 1 I

Fig. 8 is a perspective View showing the roll assembly being used inrolling straight flanged sections.

Fig. 9 is a side elevational view of a further modification of the rollassembly including a modified form of the roll which constitutes one ofthe characteristic features of the presing flanges. According to thispriorprac tice a thick billetor biscuit 20 is rolled in a mill havingthe axes ofthe rolls parallel to the axis of the flange and with thefeed taken in a direction normal to the axis as in a tire mill. Theresulting product 21 will assume a shape substantially as shown in 'Fig.2, and still requires considerable machining toproduce the finishedflange which is indicated by dotted lines at 22. The port-ion which mustbe machined away in order to produce the finishedflange is indicated at23.

As-above indicated, the reason the billet' is not rolled with a hub morenearly approximati'ng the finished hub is because of the unequaldistribution of the metal. This could not be done even though the 'castbillet had a hub on it. Suppose, for instance, it wasattempted to roll ahigh hub flange by the present process from either a flat billet asshown in Fi 1 or from a billet with a hub.

It -1S quite obvious for a given bite of .the

- rolls taken in a direction normal to the axis of the flange that thepercent reduction of the flange body will be less than the percentreduction of thehub and for this reason the hub will elongate at agreater rate than the flange body. This will, of course, give a flangewith a bell-mouthed hub, and if the rolling is carried far enough, onewith a scalloped hub will result.

; shown in Figs. 3 and '4.

In any flange there is a certain definite relation'between hub-thicknessand flange thickness. If this same relation is maintained in the billet24 such as shown in dotted line in Fig. 4 and the rolling is directed ina line ba,

the percentage reduction on'both hub 25 and flange body 26 will be thesame and the elongation in both these members will, therefore,

be identical. p

Since abillet 24 as shown in Fig. 4 is quite expensive to make, it ispossible to make a: hub flange from a flat billet or biscuit"27 as shownin Fig. 3, the only requirement-be ing that the'rollin'g be done in thedirection of the'line be, and that the point of the rollbe placed insuch an initial position that the ratio between distance 06 andthickness of billet 0a, shall be the same as the ratio' of finished hubthickness to finished flange thickness. v

This type ofrolling can be accomplished on; either of the machines shownin Figs. 5

and 6.

In Fig. '5 the flange receives a pure rolling action on allsurfaces,whilein Fig. 6 it is i supported on a revolving disc 28 and is rolledagainst the face of this disc and also against.

a central projecting pin or roll 29. The machine or roll assembly shownin Figs. 5 and 7 comprises a-pluralityof supporting rolls 30 and 33which may be either driven or merely idle rolls, or partly driven andpartly idle rolls. In the: drawings the rolls 30 are mounted to rotateidly and the roll '33 is driven from-a suitable source of power.

Positioned above theroll 33 is shown still anotherroll 34. This roll isshaped especially for carrying out the method herein dis.

closed and has the form of a pair of trunare shown as meeting at rightangles. However, it will be understood that for producing a hub sectionand an abutting section on the flange'which sections vary in thickness,as for example, thinner either at the outer edges or at the point ofintersection of the hub and body portions on eitheror both of suchportions', the rolling surfaces may intersect at an angle greater thanor less than 90. The roll 34 is mounted axially on a shaft 37 and maybeeither driven or idle. In order to simplify the apparatus it ispreferredio omit mechanismfor driving the roll 34. However, means areprovided for adjusting the roll 34 to and from the billet or blank 38being worked upon so'as to control the bite taken or the rate ofreduction. \Vhile the means for supporting and adjusting the roll 34 mayassume various forms, in the drawing the shaft carrying the roll 34 isshown asmounted in bearings 39 formed in the ends of a yoke 40 which inturn is mounted on'the end of a .rack bar 41 which is adapted to bereciprocated in the housing 42 by means of the pinion 43 orothersuit-able means.

I As is indicated in the drawing the roll 34 is so mounted that itfollows such a path, as

'drivenand may or may not be adjusted toward and away from the rolls -33and 34.,

Adjustable guide rolls 48 are also provided. In Fig; 6, in lieu of therolls 30 and 33, a revolving disc 28 carried by a vertical shaft 49 isprovided, and. in lieu of the inner roll 4'? a central pin29 alsomounted on the'shaft'49 is provided. It will be understood, however,that instead ofmounting the central pin orroll 29 on the shaft 49, itmay be supported from'above in any suitable manner. I

In Fig. 8, a rectangular billet or blank 50. is shown as beingrolled bymeans of the rolls 33, 34 and '47. Guide rolls 48 and supporting rolls30 are also. provided.

similar in itsprinciple of operation to roll 34 above described but witha plurality ofdouble frusto-conicalsections is provided. This roll inadditionto havingrolling surfaces meeting on the line of intersection 45has shoulders defining surfaces 52 and 53 intersecting on' the line 54and surfaces 55 and 56-- intersec ting on theline 57, The surface 53 isadapted to engagethe outer peripheral surface of thebody of the'flangebeing rolled and to cooperate with a shoulder 58 carried by the roll 33in forming such peripheral surface to a finished dimension. Similarlythe rolling surface 55 engages .the upper edge portion of the hub andcooperates with a shoulder 59 on the roll 47 to roll the upper edgeportion of the hub to a finished dimension.

According to the modification shown in Fig. 10 a roll 60 is provided.This rollis similar in general form to roll 51 except that it hasshbulder portions defining the surfaces 53 and 55 which portions extendoutward a sufficient distance to entirely,close, respectively, the spacebetween the roll 60 and the roll 33 at the outside peripheral edge ofthe body of the flange, and the space between the roll 47 and the roll60 at the upper edge of the hub.

Inthe modification shown in Fig. 11 a roll 34 having a single doublefrusto-conical section is used in conjunction with rolls 33 and 47having shoulder portions 58' and 59' extending outward from the bodyportions of the respective rolls a sufficient distance to close thespaces between the body portions of the rolls 33 and 4 and the opposingportions of the roll 34.

In Figs. 9, 10 and 11 the rolls and the flanges being worked are shownin the position they assume at the end of the rolling operation and atthe time when the flange has been brought to its finished dimensions Itwill be understood that either an annular billet with a hub formedthereon or a plain annular blank or biscuit may be operated upon thesame as in the case of the modifications previously described. Also, ifdesired, the flange or other member being'rolled may be broughtsubstantially to its finished dimensions with a roll assembly such asshown in Figs. 5 and.6 and then transferred to a roll assembly such asany one of those shown in Figs. 9, 10 and 11" and further rolled tofinished dimensions. It will also be understood that the modificationsshown in Figs. 9, 10 and 11 may be used in rolling rectangular billetsor blanks such as shown in Fig. 8.

In Figs. 9, 10 and 11 the auxiliary supporting rolls and guide rollshave not been shown. However, it is to be understood that such rolls areprovided, or other suitable'means used for supporting or guiding theblank.

lVhile the invention has been described with particular reference to theapparatus shown, it is to be understood that the method may be carriedout with other forms of ap paratus and that various modifications andchanges in the aparatus shown and described may be made withoutdeparting from the invention. Accordingly, the invention is not deemedto be limited other than as indicated in the appended claims.

- What I claim is:

1. Process of forming a metal article having an extended flange portion,in which the flange and body portions of the article are developedsimultaneously and in the same proportion as these portions bear in thefinished article, which comprises rolling a blank of rectangular crosssection with a roll having rolling surfaces disposed at right angles andcausing said roll to advance, in the course of the reduction of theblank, from a predetermined point on one surface of the blank in a pathdefined by a straight line passing through the line of intersectionofthe surfaces of said blank remote from the portion being worked on bysaid roll.

2. Process of forming annular metal articles having a high hub portionand an extended flange portion, in which the flange and hub portions ofthe article are developed simultaneously and in the same proportion asthese portions bear in the finished article,

which comprises rolling a blank of rectan ular cross section with a rollhaving rolling surfaces dlsposed at right angles and causing said rollto advance, in the course of the reduction of the blank, from apredetermined point on one surface of the b1ank in a path defined by astraight line passing through the line of intersection of the surfacesof said blank remote from the portion being worked on by said roll. I

3. Process of forming annular metal articles having a high hub portionand an extended flange portion in which the flange and hub portions ofthe article are developed snnultaneously and in the same proportion asthese portions bear in the finished article, which comprises applyingrolling pressure to a portion only of a surface of an annular blank andcausing said roll to advance con-. tinuously, in the course of thereduction of the blank, laterally as well asperpendicularly to thesurface upon which pressure is being applied, and simultaneously forgingthe remainder of the said surface outward laterally with respect to thedirection of advance of said roll.

4. Process of forming a metal article having an extended flange portion,in which the flange and body portions of the article are developedsimultaneously and in the same proportion as these portions bear in thefinished article, which comprises applying rolling pressure to a portiononly of a surface of a blank and causing said roll to advancecontinuously, in the course of the reduction of the blank, laterally aswell as perpendicularly to the surface upon which pressure is beingapplied, and simultaneously forging the remainder of the said surfaceoutward a body portion of cross-section different from that of the saidflange'portion, comprising a roll havin rolling surfaces intersecting ina plane su stantially at right angles to the axis of rotation of saidroll, means for supporting a metal blank of initiallyrectangularcross-section inoperative relation to said roll, and meansfor moving-said roll against a portion but not all of the surface ofoneside of said flange and for causing it to advance in the course ofthe reduction of the blank in a straight path and in a directionsubstantially at right angles to the axis of ';aid roll and at an angleto said blank surace.

6. Apparatus forforming flanged metal articles, comprising .a rollhaving rolling atright angles to the axis of rotation of said roll,means for supporting an annular metal blank in operative relation tosaid roll, means for causing relative movement between said roll andsaid blank, in the course of the re; duction of the blank, in a straightpath and in a direction substantially at right angles to the axis ofsaid roll, and means causing the annular blank to revolve in rollingcontact with said roll.

7. Apparatus for forming flanged metal articles, comprising rolls 'forsupporting an annular blank, a roll mounted above said blank and havingrolling surfacesintersecting in a plane substantially at right angles tothe axis of rotation of said roll, a'roll engaging the inner surface ofsaid annular blank, and means for adjusting the rolls to and fromone'another and for causing said blank to revolve in rollingengagement-with said rolls.

8 Apparatus for forming flanged metal articles, comprising a roll havingrolling sursurfaces intersecting in a plane substantially facesintersecting in a plane substantially at right angles to the axis ofrotation of said roll, means for causing relative-movement between saidroll. and a blank of initially" rectangular cross-section, in the courseof the i bdu'ction of the blank, in a. path defined by a straight linepassing through the line of ins tersection of thesurfaces of said blankre mote from the portions being worked by said roll, and means forcausing rollingcontact between said roll and said blank.

9.: Process of forming annular metal articles having a high hub portionand an extended flange portion, in which the flange and hub portions ofthe "article are devel- .oped simultaneously in the same proportion asthese portions bear in the-finished articles, which comprises forming, ametal .blank with hub and flange portions, bringing a rolling memberinto contact-withjhe intersecting surfaces of said huband-flangepOrtiOnS, imparting rolling pressure from said member to saidblank, and causing said member to adyance, in the course of thereduction of the

